Proper Start-up and Shut Down Procedures for Cone Crusher
Correct startup and shutdown sequences are critical for cone crusher operation, affecting everything from equipment longevity to operator safety. This comprehensive guide covers essential procedures for both hydraulic and mechanical cone crusher.
Pre-Startup Inspection Checklist
Before initiating startup procedures, perform these essential checks:
- Lubrication System: Verify oil level is correct and reservoir is full
- Crusher Hopper: Inspect for foreign objects or material buildup
- Wear Parts: Check mantle and concave for excessive wear
- Drive Belts: Ensure proper tension and alignment
- Hydraulic System: Confirm hydraulic pressure settings and check for leaks
- Safety Guards: Verify all guards are securely in place
- Fasteners: Check all bolts for proper torque
Cone Crusher Startup Procedure
Step 1: Lubrication System Activation
Always start the lubrication system 5-10 minutes before crusher operation:
- Engage the lubrication system pump
- Verify oil flow to all bearings
- Confirm proper oil pressure (typically 15-25 psi)
- Check oil temperature reaches optimal operating range
Step 2: Crusher Startup
- Ensure crusher chamber is empty of material
- Start crusher motor with no-load
- Allow crusher to run idle for 2-3 minutes
- Listen for abnormal noises/vibrations
- Monitor amps/volts for unusual readings
Step 3: Feeding the Crusher
- Begin feeding material at reduced rate
- Gradually increase to normal operating capacity
- Maintain consistent feed distribution
- Avoid “packed crushing” conditions
Cone Crusher Shutdown Procedure
Step 1: Feed Reduction
- Slowly decrease feed rate
- Allow crusher to process remaining chamber material
- Never shut down with full chamber
Step 2: Motor Shutdown
- Confirm chamber is empty
- Stop crusher motor
- Allow rotation to completely stop
Step 3: Lubrication System Shutdown
- Continue lubrication for 5-10 minutes after shutdown
- This cools bearings and flushes contaminants
- Monitor oil temperature during cool-down
- Shut off lubrication system
Crucial Safety Considerations
- Always wear proper PPE – hard hat, safety glasses, hearing protection
- Never bypass safety interlocks
- Lock-out/tag-out during maintenance
- Establish proper communication protocols
- Keep clear of moving components
Troubleshooting Common Startup/Shutdown Issues
| Issue | Possible Cause | Solution |
|---|---|---|
| High vibration at startup | Worn bearings, unbalanced components | Inspect/replace bearings, check balance |
| Low oil pressure | Clogged filters, pump issues | Replace filters, inspect pump |
| Crusher won’t turn | Material jam, mechanical failure | Clear chamber, inspect components |
| Overheating at shutdown | Insufficient cool-down time | Extend lubrication operation |
Maintenance Best Practices
- Keep detailed operational logs
- Schedule regular lubrication system maintenance
- Inspect wear parts weekly
- Monitor vibration patterns
- Follow manufacturer’s maintenance schedule
Proper startup and shutdown procedures significantly extend cone crusher life while improving safety and reducing downtime. Always consult your specific equipment manuals for model-specific requirements.
Seasonal Operation Considerations
For crusher operating in variable climates:
- Cold Weather: Use low-temperature oils, preheat lubrication system
- Hot Weather: Monitor oil cooling efficiency, increase inspections
- Humid Conditions: Watch for moisture contamination in lubrication
